Secondary slurry flow path member with shut-off valve activated by dissolvable flow tubes

ABSTRACT

A downhole secondary flow path member includes a tubular having a first end portion, a second end portion, and an intermediate portion having a flow passage extending therebetween. The tubular includes a first opening arranged adjacent the first end portion and a second opening arranged adjacent the second end portion. A valve assembly is provided on the tubular at the first opening. The valve assembly includes a valve member. A flow tube runs along at least a portion of the tubular. The flow tube has a dissolvable end section mechanically linked to the valve assembly. The dissolvable end segment selectively shields the valve member from exposure to downhole fluids. The valve member changes from an open position to a closed position following dissolution of the dissolvable end segment.

BACKGROUND

Downhole operations often include a downhole string that extends into aformation having multiple zones. One or more of the multiple zones maybe isolated from others of the zones. In this manner, recovery,treatment and/or other operations may be carried out in each zoneindependent of other zones. At times, it is desirable to perform anoperation that sends fluid to or receives fluid from one zone through abypass passage that traverses other zones. The bypass passage isfluidically isolated from the other zones. After the operation, it isoften times desirable to close the bypass passage. Current techniquesfor closing the bypass passage require actions that originate uphole andoften times include running additional tools and/or fluid downhole tooperate a valve, sleeve, or the like.

SUMMARY

A downhole secondary flow path member includes a tubular having a firstend portion, a second end portion, and an intermediate portion having aflow passage extending therebetween. The tubular includes a firstopening arranged adjacent the first end portion and a second openingarranged adjacent the second end portion. A valve assembly is providedon the tubular at the first opening. The valve assembly includes a valvemember. A flow tube runs along at least a portion of the tubular. Theflow tube has a dissolvable end section mechanically linked to the valveassembly. The dissolvable end segment selectively shields the valvemember from exposure to downhole fluids. The valve member changes froman open position to a closed position following dissolution of thedissolvable end segment.

A method of controlling fluid flow through a secondary flow memberincludes directing fluid into a flow tube having a dissolvable endportion exposed to a downhole fluid, passing the fluid into a valveassembly having a selectively closeable valve member, guiding the fluidfrom the valve assembly into an opening formed in a tubular, and closingthe valve member in response to a dissolution of the dissolvable endportion resulting from exposure to the downhole fluid.

A downhole secondary flow path member includes a first valve assemblyand a second valve assembly. At least one of the first and second valveassemblies includes a selectively swellable valve member including amaterial that expands when exposed to a downhole fluid. One or more flowtubes fluidically connect the first valve member and the second valvemember. The one or more flow tubes include at least one dissolvable endsegment mechanically linked to the one of the first and second valveassemblies including the selectively swellable valve member. The atleast one dissolvable end segment selectively shielding the selectivelyswellable valve member from exposure to downhole fluids, wherein thevalve member changes from an open position to a closed positionfollowing dissolution of the dissolvable end segment.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings wherein like elements are numbered alikein the several Figures:

FIG. 1 depicts an uphole system operatively connected to a downholestring having a secondary flow path member, in accordance with anexemplary embodiment;

FIG. 2 depicts a partially cut-away view of the secondary flow pathmember of FIG. 1;

FIG. 3 depicts a cross-sectional view of a valve assembly having a valvemember of the secondary flow path member of FIG. 2;

FIG. 4 depicts a dissolvable end of a flow tube following dissolutionexposing the valve member of FIG. 3;

FIG. 5 depicts the valve member of FIG. 4 in a closed position followingdissolution of the dissolvable end portion of the flow tube, inaccordance with an aspect of an exemplary embodiment; and

FIG. 6 depicts a secondary flow path member in accordance with anotheraspect of an exemplary embodiment.

DETAILED DESCRIPTION

A resource exploration system, in accordance with an exemplaryembodiment, is indicated generally at 2, in FIG. 1. Resource explorationsystem 2 should be understood to include well drilling operations,resource extraction and recovery, CO₂ sequestration, and the like.Resource exploration system 2 may include an uphole system 4 operativelyconnected to a downhole system 6. Uphole system 4 may include pumps 8that aid in completion and/or extraction processes as well as fluidstorage 10. Fluid storage 10 may contain a gravel pack fluid or slurry(not shown) that is introduced into downhole system 6.

Downhole system 6 may include a downhole string 20 that is extended intoa wellbore 21 formed in formation 22. Downhole string 20 may include anumber of connected downhole tools or tubulars 24. One of tubulars 24may include secondary flow path member 28. Formation 22 may include anumber of zones, one of which is indicated at 30. Secondary flow pathmember 28 may include a sand screen 33 that facilitates a fluid exchangebetween downhole string 20 and zone 30. As will be detailed more fullybelow, secondary flow path member 28 also allows fluids, such as thegravel pack slurry from fluid storage 10 to be pumped downhole.

In accordance with an exemplary embodiment illustrated in FIG. 2,secondary flow path member 28 includes a first tubular 42 having a body44 including a first end portion 48, a second end portion 50 and anintermediate portion 51. In the exemplary embodiment shown, first endportion 48 connects with tubulars 24 extending uphole while second endportion 50 connects with tubulars extending downhole. In accordance withan aspect of an exemplary embodiment, intermediate portion 51 includesan outer surface (not separately labeled) which may support sand screen33 and an inner surface 54. First tubular 42 also includes a firstopening 56 arranged toward first end portion 48 and a second opening 58arranged toward second end portion 50.

A second tubular 63 is arranged within first tubular 42. Second tubular63 include a body 65 having a first end 68, a second end 69 and anintermediate zone 70 extending therebetween. Intermediate zone 70includes an outer surface 72 that, together with inner surface 54 offirst tubular 42 defines a flow passage 78 that is generally definedbetween first and second openings 56 and 58. Second end 69 also carriesone or more seals, such as indicated at 81 in FIG. 3 that provide afluid tight connection between first and second tubulars 42 and 63.Additional seals (not separately labeled) may be arranged at first end68.

In further accordance with an aspect of an exemplary embodiment,secondary flow member 28 includes a first valve assembly arranged nearfirst end portion 48 and a second valve assembly 92 arranged near secondend portion 50. A first plurality of fluid transport members or flowtubes 94 extend from uphole and may fluidically connect fluid storage 10with first valve assembly 90 and a second plurality of fluid transportmembers or flow tubes 96 may connect with, and extend downhole relativeto, second valve assembly 92 and extends downhole. As will be detailedmore fully below, secondary flow path member 28 provides a bypass thatallows a fluid from, for example, fluid storage 10, to bypass by zone 30without being in direct contact with fluids entering tubular 24 throughsand screen 52.

As each valve assembly 90 and 92 and first and second pluralities offlow tubes 94 and 96 may be substantially similarly formed, a detaileddescription will follow with respect to FIG. 3 in describing secondvalve assembly 92 and second plurality of flow tubes 96 with anunderstanding that first valve assembly 90 and first plurality of flowtubes 94 may include similar structure.

First valve assembly 90 includes a valve body 110 having a flange member112 that connects to first tubular 42 through a seal 114 and a second,cantilevered end 115. First valve assembly 90 includes a cominglingchamber 118 that is arranged across second opening 58. Valve assembly 92also includes a valve member 120 that selectively closes flow passage78. In accordance with an aspect of an exemplary embodiment, valvemember 120 is formed from a swellable material that expands when exposedto downhole fluids. Thus, in the exemplary embodiment shown, valveassembly 92 includes a shield element 122 that prevents and/orsubstantially reduces contact between valve member 120 and downholefluids. In accordance with another aspect of an exemplary embodiment,valve assembly 92 may include a spring activated valve that closes flowpassage 78.

In further accordance with an exemplary embodiment, second flow tube 96is formed with a dissolvable end section 133 that engages with valvemember 120. In accordance with an aspect of an exemplary embodiment,dissolvable end section 133 may be formed from a material that isdistinct from remaining portions of second flow tube 96. In accordancewith one aspect of an exemplary embodiment, dissolvable end section 133may be formed from a controlled electrolytic metal (CEM) such asInTallic™ from Baker Hughes Incorporated Houston Tex. which dissolvesover a period of time when exposed to downhole fluids. Of course, itshould be understood that dissolvable end portion 133 may be formed froma variety of materials that dissolve when exposed to downhole fluids.Further, the particular material and/or materials chosen may be tailoredto establish a desired dissolution rate for dissolvable end portion 133.

In operation, a fluid, such as a gravel pack slurry is introduced intofirst flow tube 94. The slurry passes into first valve assembly 90 andthrough first opening 56. The slurry travels along flow passage 78 andexits second opening 58 into valve assembly 92 and continues alongtubular 24 through second flow tube 96. In this manner, the slurry doesnot interact with other fluids passing along turbular 24 from, forexample, zone 30. After a period of time, gravel packing operationsdownhole from zone 30 are complete and dissolvable end section 133begins to dissolve as shown in FIG. 4. Once dissolved, valve member 120is exposed to downhole fluids.

Exposure to downhole fluids results in an expansion of valve member 120as shown in FIG. 5. First valve assembly 90 experiences a similardissolution and expansion. Thus, without the need for any upholeintervention, first and second valve assembly 90 and 92 are closedcutting off fluid through flow passage 78. At this point, it should beunderstood that the number if secondary flow members arranged downholemay vary. Further, it should be understood that secondary flow membermay be employed in connection with a number of operations and should notbe considered as being limited to gravel packing operations.

FIG. 6, wherein like reference numbers represent corresponding parts inthe respective views, illustrates a secondary flow path member 200 inaccordance with another aspect of an exemplary embodiment. Secondaryflow path member 200 includes a first valve assembly 202, a second valveassembly 204 and one or more flow passage tubes 210 extendingtherebetween. First valve assembly 202 is fluidically connected to firstplurality of flow tubes 94 while second valve assembly 204 isfluidically connected to second plurality of flow tubes 96. One or moreflow passage tubes 210 extend between and fluidically connect firstplurality of flow tubes 94 and second plurality of flow tubes 96 viafirst and second valve members 202 and 204. In the exemplary embodimentshown, one or more flow tubes 96 are arranged externally of secondaryflow path member 200.

In further accordance with an exemplary aspect, each valve assembly 202,204 includes a corresponding first and second selectively swellablevalve member 220 and 224 that selectively, fluidically isolates one ormore flow tubes 210 from first plurality of flow tubes 94 and secondplurality of flow tubes 96. In accordance with an aspect of an exemplaryembodiment, first and second selectively swellable valve members 220 and224 are formed from a material that expands when exposed to downholefluids.

In still further accordance with an exemplary aspect, each of one ormore flow tubes 210 includes one or more dissolvable end segments 230and 234 arranged proximate to corresponding ones of first and secondvalve assemblies 202 and 204. Dissolvable end segments 230 and 234selectively shield corresponding ones of first and second selectivelyswellable valve members from exposure to downhole fluids. In a mannersimilar to that described above, exposure to downhole fluids will, overtime, lead to dissolution of one or more dissolvable end segments 230and 234. The dissolution of one or more dissolvable end segments 230 and234 exposes corresponding ones of first and second selectively swellablevalve members 220, 224 to downhole fluids. Upon being exposed todownhole fluids, first and second selectively swellable valve members220 and 224 expand to fluidically isolate one or more flow tubes 210from first plurality of flow tubes 94 and second plurality of flow tubes96. Of course, it should be understood that while shown with two valveassemblies, secondary flow path member may include a single valve memberwith one or more flow tubes 210 having a single dissolvable end.

Set forth below are some embodiments of the foregoing disclosure:

Embodiment 1: A downhole secondary flow path member comprising: atubular including a first end portion, a second end portion, and anintermediate portion having a flow passage extending therebetween, thetubular including a first opening arranged adjacent the first endportion and a second opening arranged adjacent the second end portion; avalve assembly provided on the tubular at the first opening, the valveassembly including a valve member; and a flow tube running along atleast a portion of the tubular, the flow tube having a dissolvable endsection mechanically linked to the valve assembly, the dissolvable endsegment selectively shielding the valve member from exposure to downholefluids, wherein the valve member changes from an open position to aclosed position following dissolution of the dissolvable end segment.

Embodiment 2: The downhole secondary flow member according to embodiment1, wherein the valve assembly includes a comingling flow chamberfluidically connected with the first opening.

Embodiment 3: The downhole secondary flow member according to embodiment1, wherein the valve member comprises a swellable valve member thatexpands upon exposure to downhole fluids.

Embodiment 4: The downhole secondary flow member according to embodiment1, wherein the dissolvable end segment is formed from a materialdistinct from a remaining portion of the flow tube.

Embodiment 5: The downhole secondary flow member according to embodiment4, wherein the dissolvable end segment is formed from a controlledelectrolytic metal (CEM) material.

Embodiment 6: The downhole secondary flow member according to embodiment1, further comprising: another a valve assembly provided on the firsttubular at the second opening, the another valve assembly includinganother valve member activatable upon exposure to downhole fluids.

Embodiment 7: The downhole secondary flow member according to embodiment6, further comprising: another flow tube running along at least aportion of the second tubular downhole relative to the flow tube, theanother flow tube having a dissolvable end section mechanically linkedto the another valve assembly, the dissolvable end segment selectivelyshielding the another valve member from exposure to downhole fluids.

Embodiment 8: The downhole secondary flow member according to embodiment7, wherein the another flow tube is fluidically connected to the flowtube through the tubular.

Embodiment 9: The downhole secondary flow member according to embodiment7, wherein the another valve assembly includes another comingling flowchamber fluidically connected with the comingling low chamber throughthe tubular.

Embodiment 10: The downhole secondary flow member according toembodiment 9, wherein the another comingling flow chamber is fluidicallyisolated from the comingling flow chamber following dissolution of thedissolvable flow segment.

Embodiment 11: The downhole secondary flow member according toembodiment 9, further comprising: another tubular arranged within thetubular, the another tubular having an outer wall spaced from the innerwall of the tubular to form a portion of the flow passage.

Embodiment 12: The downhole secondary flow member according toembodiment 11, wherein the another comingling flow chamber isfluidically connected to the flow comingling flow chamber through theflow passage.

Embodiment 13: The downhole secondary flow member according toembodiment 1, further comprising: an uphole system one or more pumps afluid storage system fluidically connected to the tubular through adownhole string.

Embodiment 14: A downhole flow member as in embodiment 1, wherein theflow tube includes a first plurality of flow tubes fluidically connectedto the first opening and running along the portion of the tubular upholeand a second plurality of flow tubes fluidically connected to the secondopening and running along another portion of the tubular downhole, thefirst and second pluralities of flow tubes fluidically connecting thefirst and second end portions.

Embodiment 15: A method of controlling fluid flow through a secondaryflow member comprising: directing fluid into a flow tube having adissolvable end portion exposed to a downhole fluid; passing the fluidinto a valve assembly having a selectively closeable valve member;guiding the fluid from the valve assembly into an opening formed in atubular; and closing the valve member in response to a dissolution ofthe dissolvable end portion resulting from exposure to the downholefluid.

Embodiment 16: The method of embodiment 15, wherein closing the valvemember includes expanding the valve member in response to exposure tothe downhole fluid.

Embodiment 17: The method of embodiment 15, wherein guiding the fluidfrom the valve member includes passing the along the tubular bypassing aformation zone.

Embodiment 18: The method of embodiment 17, wherein passing the fluidfrom the comingling chamber includes passing the fluid into a fluidpassage defined between a first tubular and a second tubular.

Embodiment 19: The method of embodiment 17, further comprising: passingthe fluid from the tubular into another valve assembly arranged downholeof the valve assembly.

Embodiment 20: The method of embodiment 18, further comprising: exposinganother valve member of the another valve assembly to downhole fluidfollowing dissolution of another dissolvable end portion of another flowtube coupled to the another valve assembly.

Embodiment 21: The method of embodiment 15, wherein passing the fluidinto the flow tube includes pumping the fluid from an uphole systemalong a downhole string through the flow tube.

Embodiment 22: A downhole secondary flow path member comprising: a firstvalve assembly; a second valve assembly, at least one of the first andsecond valve assemblies including a selectively swellable valve memberincluding a material that expands when exposed to a downhole fluid; andone or more flow tubes fluidically connecting the first valve member andthe second valve member, the one or more flow tubes having at least onedissolvable end segment mechanically linked to the one of the first andsecond valve assemblies including the selectively swellable valvemember, the at least one dissolvable end segment selectively shieldingthe selectively swellable valve member from exposure to downhole fluids,wherein the valve member changes from an open position to a closedposition following dissolution of the dissolvable end segment.

The teachings of the present disclosure may be used in a variety of welloperations. These operations may involve using one or more treatmentagents to treat a formation, the fluids resident in a formation, awellbore, and/or equipment in the wellbore, such as production tubing.The treatment agents may be in the form of liquids, gases, solids,semi-solids, and mixtures thereof. Illustrative treatment agentsinclude, but are not limited to, fracturing fluids, acids, steam, water,brine, anti-corrosion agents, cement, permeability modifiers, drillingmuds, emulsifiers, demulsifiers, tracers, flow improvers etc.Illustrative well operations include, but are not limited to, hydraulicfracturing, stimulation, tracer injection, cleaning, acidizing, steaminjection, water flooding, cementing, etc.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application. For example, “about”can include a range of ±8% or 5%, or 2% of a given value.

While one or more embodiments have been shown and described,modifications and substitutions may be made thereto without departingfrom the spirit and scope of the invention. Accordingly, it is to beunderstood that the present invention has been described by way ofillustrations and not limitation.

1. A downhole secondary flow path member comprising: a tubular includinga first end portion, a second end portion, and an intermediate portionhaving a flow passage extending therebetween, the tubular including afirst opening arranged adjacent the first end portion and a secondopening arranged adjacent the second end portion; a valve assemblyprovided on the tubular at the first opening, the valve assemblyincluding a valve member; and a flow tube running along at least aportion of the tubular, the flow tube having a dissolvable end sectionmechanically linked to the valve assembly, the dissolvable end segmentselectively shielding the valve member from exposure to downhole fluids,wherein the valve member changes from an open position to a closedposition following dissolution of the dissolvable end segment.
 2. Thedownhole secondary flow member according to claim 1, wherein the valveassembly includes a comingling flow chamber fluidically connected withthe first opening.
 3. The downhole secondary flow member according toclaim 1, wherein the valve member comprises a swellable valve memberthat expands upon exposure to downhole fluids.
 4. The downhole secondaryflow member according to claim 1, wherein the dissolvable end segment isformed from a material distinct from a remaining portion of the flowtube.
 5. The downhole secondary flow member according to claim 4,wherein the dissolvable end segment is formed from a controlledelectrolytic metal (CEM) material.
 6. The downhole secondary flow memberaccording to claim 1, further comprising: another a valve assemblyprovided on the first tubular at the second opening, the another valveassembly including another valve member activatable upon exposure todownhole fluids.
 7. The downhole secondary flow member according toclaim 6, further comprising: another flow tube running along at least aportion of the second tubular downhole relative to the flow tube, theanother flow tube having a dissolvable end section mechanically linkedto the another valve assembly, the dissolvable end segment selectivelyshielding the another valve member from exposure to downhole fluids. 8.The downhole secondary flow member according to claim 7, wherein theanother flow tube is fluidically connected to the flow tube through thetubular.
 9. The downhole secondary flow member according to claim 7,wherein the another valve assembly includes another comingling flowchamber fluidically connected with the comingling low chamber throughthe tubular.
 10. The downhole secondary flow member according to claim9, wherein the another comingling flow chamber is fluidically isolatedfrom the comingling flow chamber following dissolution of thedissolvable flow segment.
 11. The downhole secondary flow memberaccording to claim 9, further comprising: another tubular arrangedwithin the tubular, the another tubular having an outer wall spaced fromthe inner wall of the tubular to form a portion of the flow passage. 12.The downhole secondary flow member according to claim 11, wherein theanother comingling flow chamber is fluidically connected to the flowcomingling flow chamber through the flow passage.
 13. The downholesecondary flow member according to claim 1, further comprising: anuphole system one or more pumps a fluid storage system fluidicallyconnected to the tubular through a downhole string.
 14. A downhole flowmember as in claim 1, wherein the flow tube includes a first pluralityof flow tubes fluidically connected to the first opening and runningalong the portion of the tubular uphole and a second plurality of flowtubes fluidically connected to the second opening and running alonganother portion of the tubular downhole, the first and secondpluralities of flow tubes fluidically connecting the first and secondend portions.
 15. A method of controlling fluid flow through a secondaryflow member comprising: directing fluid into a flow tube having adissolvable end portion exposed to a downhole fluid; passing the fluidinto a valve assembly having a selectively closeable valve member;guiding the fluid from the valve assembly into an opening formed in atubular; and closing the valve member in response to a dissolution ofthe dissolvable end portion resulting from exposure to the downholefluid.
 16. The method of claim 15, wherein closing the valve memberincludes expanding the valve member in response to exposure to thedownhole fluid.
 17. The method of claim 15, wherein guiding the fluidfrom the valve member includes passing the along the tubular bypassing aformation zone.
 18. The method of claim 17, wherein passing the fluidfrom the comingling chamber includes passing the fluid into a fluidpassage defined between a first tubular and a second tubular.
 19. Themethod of claim 17, further comprising: passing the fluid from thetubular into another valve assembly arranged downhole of the valveassembly.
 20. The method of claim 18, further comprising: exposinganother valve member of the another valve assembly to downhole fluidfollowing dissolution of another dissolvable end portion of another flowtube coupled to the another valve assembly.
 21. The method of claim 15,wherein passing the fluid into the flow tube includes pumping the fluidfrom an uphole system along a downhole string through the flow tube. 22.A downhole secondary flow path member comprising: a first valveassembly; a second valve assembly, at least one of the first and secondvalve assemblies including a selectively swellable valve memberincluding a material that expands when exposed to a downhole fluid; andone or more flow tubes fluidically connecting the first valve member andthe second valve member, the one or more flow tubes having at least onedissolvable end segment mechanically linked to the one of the first andsecond valve assemblies including the selectively swellable valvemember, the at least one dissolvable end segment selectively shieldingthe selectively swellable valve member from exposure to downhole fluids,wherein the valve member changes from an open position to a closedposition following dissolution of the dissolvable end segment.